U.S. patent number 10,499,704 [Application Number 15/604,890] was granted by the patent office on 2019-12-10 for sole for an article of footwear having regionally varied auxetic structures.
This patent grant is currently assigned to NIKE, Inc.. The grantee listed for this patent is NIKE, Inc.. Invention is credited to Tory M. Cross, Bryan N. Farris, Elizabeth Langvin.
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United States Patent |
10,499,704 |
Cross , et al. |
December 10, 2019 |
Sole for an article of footwear having regionally varied Auxetic
structures
Abstract
A sole for article of footwear includes a midsole component
having an inner surface and an outer surface opposite the inner
surface. A plurality of blind holes each extends from the outer
surface toward the inner surface. The plurality of blind holes are
arranged in an auxetic configuration in the outer surface. Each
hole in the plurality of holes extends towards the inner surface.
The plurality of blind holes is arranged in a pattern that provides
a tunable performance characteristic. The patterns of blind holes
vary between different regions of the midsole component to provide
different types of responses in the different regions.
Inventors: |
Cross; Tory M. (Portland,
OR), Farris; Bryan N. (North Plains, OR), Langvin;
Elizabeth (Sherwood, OR) |
Applicant: |
Name |
City |
State |
Country |
Type |
NIKE, Inc. |
Beaverton |
OR |
US |
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Assignee: |
NIKE, Inc. (Beaverton,
OR)
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Family
ID: |
59788316 |
Appl.
No.: |
15/604,890 |
Filed: |
May 25, 2017 |
Prior Publication Data
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Document
Identifier |
Publication Date |
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US 20170258178 A1 |
Sep 14, 2017 |
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Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
Issue Date |
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15398750 |
Jan 5, 2017 |
10271615 |
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15389844 |
Dec 23, 2016 |
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14643121 |
Mar 10, 2015 |
9538811 |
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14643427 |
Mar 10, 2015 |
9549590 |
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14030002 |
Sep 18, 2013 |
9402439 |
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14030002 |
Sep 18, 2013 |
9402439 |
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
A43B
13/122 (20130101); A43B 13/188 (20130101); A43B
13/02 (20130101); A43B 5/00 (20130101); A43B
1/0009 (20130101); A43B 13/14 (20130101); A43B
13/187 (20130101); A43B 13/28 (20130101); A43B
13/38 (20130101); A43B 13/125 (20130101); A43B
13/186 (20130101); A43B 3/0073 (20130101); A43B
13/181 (20130101); A43B 13/141 (20130101) |
Current International
Class: |
A43B
13/02 (20060101); A43B 13/28 (20060101); A43B
13/38 (20060101); A43B 5/00 (20060101); A43B
3/00 (20060101); A43B 1/00 (20060101); A43B
13/14 (20060101); A43B 13/18 (20060101); A43B
13/12 (20060101) |
References Cited
[Referenced By]
U.S. Patent Documents
Foreign Patent Documents
Primary Examiner: Hurley; Shaun R
Assistant Examiner: Nguyen; Bao-Thieu L
Attorney, Agent or Firm: Quinn IP Law
Parent Case Text
CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a continuation in part of U.S. patent
application Ser. No. 15/398,750, filed Jan. 5, 2017, which is a
continuation of U.S. Patent Publication Number 2015/0245686,
currently U.S. Ser. No. 14/643,121, issued on Jan. 10, 2017 as U.S.
Pat. No. 9,538,811, titled "Sole Structure with Holes Arranged in
Auxetic Configuration", and filed on Mar. 10, 2015, which is a
continuation in part of U.S. Patent Application Publication Number
2015/0075033, currently U.S. Ser. No. 14/030,002, titled "Auxetic
Structures and Footwear with Soles Having Auxetic Structures", and
filed Sep. 18, 2013. This application is also a continuation in
part of U.S. patent application Ser. No. 15/389,844, filed on Dec.
23, 2016, which is a divisional of U.S. Pat. No. 9,549,590 issued
on Jan. 24, 2017, which is a continuation in part of U.S. Pat. No.
9,402,439 issued on Aug. 2, 2016, the entire disclosures of each of
which are hereby incorporated by reference.
Claims
What is claimed is:
1. A method of customizing a sole comprising: determining a
performance characteristic for a portion of the sole; correlating
the performance characteristic to an attribute of a plurality of
blind holes; and forming the plurality of blind holes in the sole,
wherein the plurality of blind holes are arranged on the sole to
form an auxetic structure, the auxetic structure having an
attribute that imparts a performance characteristic to the portion
of the sole.
2. The method of claim 1, wherein determining the performance
characteristic includes measuring a heel strike force; and wherein
correlating the performance characteristic includes correlating the
heel strike force to a blind hole depth pattern that tunes
cushioning in a heel portion of the sole.
3. The method of claim 1, further comprising: determining a first
tunable performance characteristic for a first portion of the sole;
determining a second tunable performance characteristic for a
second portion of the sole; forming a first plurality of blind
holes in the first portion of the sole, wherein the first plurality
of blind holes is arranged in a first pattern to form a first
auxetic structure, wherein the first pattern imparts the first
tunable performance characteristic to the first portion; forming a
second plurality of blind holes in the second portion of the sole
in a second pattern to form a second auxetic structure, wherein the
second pattern imparts the second tunable performance
characteristic to the second portion; and wherein the first pattern
is different from the second pattern so that the first tunable
performance characteristic is different from the second tunable
performance characteristic.
4. The method according to claim 3, wherein: determining a tunable
performance characteristic includes measuring a heel strike force
in a heel portion and a push off force in a forefoot portion; and
wherein correlating the tunable performance characteristic includes
correlating the heel strike force to a first blind hole depth
pattern that tunes cushioning in the heel portion of the sole and
correlating the push off force to a second blind hole depth pattern
that tunes stability in the forefoot portion.
5. The method of claim 3, wherein the first portion of the sole is
the heel portion, and the second portion of the sole is the
forefoot portion.
6. The method of claim 3, wherein the first and second tunable
performance characteristics each include at least one of: a
cushioning response, traction, stability, and support.
7. The method of claim 1, wherein determining a performance
characteristic for a portion of the sole includes at least one of:
measuring plantar pressure of a foot using a plantar pressure
measurement system; or measuring geometric information of the foot
using a foot measuring or imaging apparatus; and superimposing the
measured plantar pressure or measured geometric information to a
template of the sole.
8. The method of claim 7, wherein forming the plurality of blind
holes in the sole includes cutting at least a portion of the
plurality of blind holes into the sole using a laser cutting device
or hot knife process.
9. The method of claim 8, wherein the portion of the plurality of
blind holes are cut into the sole according to an aspect of the
measured plantar pressure or measured geometric information.
10. The method of claim 9, wherein the portion of the plurality of
blind holes are cut into the sole such that the sole provides a
comparatively greater cushioning response or deformation in areas
of the sole where greater plantar pressures are measured, and a
comparatively lesser cushioning response or deformation in areas of
the sole where lesser plantar pressures are measured.
11. The method of claim 1, wherein the auxetic structure expands in
both a first direction and in a second direction that is orthogonal
to the first direction when the auxetic structure is tensioned in
one or both of the first direction or the second direction.
Description
BACKGROUND
The present embodiments relate generally to articles of footwear,
and in particular to articles of footwear with uppers and sole
structures. Articles of footwear generally include two primary
elements: an upper and a sole structure. The upper may be formed
from a variety of materials that are stitched or adhesively bonded
together to form a void within the footwear for comfortably and
securely receiving a foot. The sole structure is secured to a lower
portion of the upper and is generally positioned between the foot
and the ground. In many articles of footwear, including athletic
footwear styles, the sole structure often incorporates an insole, a
midsole, and an outsole.
BRIEF DESCRIPTION OF THE DRAWINGS
The present disclosure can be better understood with reference to
the following drawings and description. The components in the
figures are not necessarily to scale, emphasis instead being placed
upon illustrating the principles of the present disclosure.
Moreover, in the figures, like reference numerals designate
corresponding parts throughout the different views
FIG. 1 is a perspective view of an embodiment of an article of
footwear having a sole with auxetic structures arranged in a
pattern on the sole
FIG. 2 is an exploded view of the article of footwear of FIG.
1;
FIG. 3 is a plan view of an embodiment of a midsole portion of the
article of footwear of FIG. 1;
FIG. 4 is a bottom isometric view of an embodiment of a sole
structure including an enlarged schematic view of a portion of the
sole structure
FIG. 5 is a bottom isometric view of an embodiment of a sole
structure including an enlarged schematic view of a portion of the
sole structure, in which the portion of the sole structure is
undergoing auxetic expansion;
FIG. 6 is a cross-sectional view of an embodiment of a heel portion
of the midsole component shown in FIG. 3 as taken along line
6-6;
FIG. 7 is a cross-sectional view of an embodiment of a forefoot
portion of the midsole component shown in FIG. 3 as taken along
line 7-7;
FIG. 8 is a schematic representation of the lateral expansion of an
embodiment of a heel midsole with auxetic structures in response to
a hard heel strike;
FIG. 9 is a schematic representation of the longitudinal and
lateral expansion of the embodiment of a heel midsole with auxetic
structures shown in FIG. 8 in response to a hard heel strike;
FIG. 10 is a schematic representation of the lateral expansion of
an embodiment of a heel midsole with auxetic structures in response
to a soft heel strike;
FIG. 11 is a schematic representation of the longitudinal and
lateral expansion of the embodiment of a heel midsole with auxetic
structures shown in FIG. 10 in response to a soft heel strike;
FIG. 12 is a schematic, longitudinal cross-sectional view of the
midsole shown in FIG. 3 in a condition at rest;
FIG. 13 is a schematic, longitudinal cross-sectional view of the
midsole shown in FIG. 3 when subjected to a heel strike;
FIG. 14 is a schematic, longitudinal cross-sectional view of the
midsole shown in FIG. 3 when subjected to a forefoot push-off
force;
FIG. 15 illustrates an embodiment of the use of a device for
obtaining three-dimensional foot data;
FIG. 16 schematically illustrates an embodiment of a virtual image
of digitized three-dimensional foot data;
FIG. 17 schematically illustrates an embodiment of a virtual image
of a template for a sole structure;
FIG. 18 schematically illustrates an embodiment of a virtual image
of a customized sole structure;
FIG. 19 is an embodiment of an influence diagram; and
FIG. 20 is an isometric view of an embodiment of a sole member
during a process of forming apertures.
DETAILED DESCRIPTION
In one aspect, the present disclosure describes a sole for an
article of footwear that includes a midsole component having an
inner surface and an outer surface opposite the inner surface. The
midsole component has a plurality of blind holes. Each blind hole
extends from the outer surface toward the inner surface. The
plurality of blind holes is arranged in an auxetic configuration in
the outer surface. Each hole in the plurality of holes extends
towards the inner surface. The blind holes are arranged in an
auxetic configuration in the outer surface of the midsole
component. The plurality of blind holes includes a first plurality
of blind holes in a first region and a second plurality of blind
holes in a second region. The first plurality of blind holes has an
attribute that is different than a similar attribute of the second
plurality of blind holes to provide the first region with a
performance characteristic that is different from the second
region. The attributes of the first region and the second regions
may be the depth of penetration of the blind holes into the midsole
component. The article of footwear may be tuned using auxetic
structures. With the auxetic structures, the ride, fit, and
cushioning across the sole structure can be customized. Such
customization is generally not possible when using a monolithic
rubber or foam sole. The heel region is configured to absorb
energy, while providing lateral stability. The midfoot region can
be stiffer than the heel region and/or non-auxetic, because the
foot exerts very little contact pressure at the midfoot portion
when compared with the heel region. The forefoot region has enough
firmness and structure to enable a good/firm push-off without
needing to dig out of a mushy cushion. The presently disclosed sole
provides another dimension of sole-response customization to
control cushioning and support. In addition, it may be preferable
to have deeper cuts in the center of the sole for cushioning, and
shallower cuts along the periphery of the sole for stability.
In another aspect, the present disclosure describes a method of
making a sole having performance characteristics. The method
includes the following steps: (1) providing a midsole component of
the sole, wherein the midsole component has a midsole thickness;
and (2) forming a plurality of blind holes in an auxetic
configuration on the midsole, wherein the plurality of blind holes
has an attribute in a portion of the sole to provide a performance
characteristic in the portion, and each of the plurality of blind
holes extends from an outer surface of the midsole component to a
depth in the midsole thickness.
In another aspect, the present disclosure describes a method of
customizing the sole. The method includes the following steps: (1)
determining a performance characteristic for a portion of the sole;
(2) correlating the performance characteristic to an attribute of a
plurality of blind holes; and (3) forming the plurality of blind
holes in the sole, wherein the plurality of blind holes are
arranged in an auxetic configuration and have the attribute,
wherein the attribute imparts the performance characteristic to the
portion of the sole.
Other systems, methods, features, and advantages of the embodiments
will be, or will become, apparent to one of ordinary skill in the
art upon examination of the following figures and detailed
description. It is intended that all such additional systems,
methods, features, and advantages be included within this
description and this summary, be within the scope of the
embodiments, and be protected by the following claims.
Articles of footwear are provided with soles that include patterns
of blind auxetic holes. The depth of penetration of the holes into
the midsole may vary in different regions of the sole to provide
different degrees of auxetic motion (expansion or contraction).
Auxetic holes with a relatively deep penetration into the thickness
of a sole structure will expand and contract to a greater degree
than auxetic holes with relatively shallow penetration into the
thickness of the sole structure. These differences in the amount of
expansion and contraction of the auxetic structures may allow a
sole to have a tunable response to applied forces. Different
patterns of the auxetic structures in the different regions provide
different responses in the different regions, depending upon the
anticipated type of desired response.
FIG. 1 is an isometric view of an embodiment of an article of
footwear 100. In the exemplary embodiment, article of footwear 100
has the form of an athletic shoe. However, in other embodiments,
the provisions discussed herein for article of footwear 100 could
be incorporated into various other kinds of footwear including, but
not limited to: basketball shoes, hiking boots, soccer shoes,
football shoes, sneakers, running shoes, cross-training shoes,
rugby shoes, baseball shoes as well as other kinds of shoes.
Moreover, in some embodiments, the provisions discussed herein for
article of footwear 100 could be incorporated into various other
kinds of non-sports related footwear, including, but not limited
to: slippers, sandals, high heeled footwear, and loafers.
For purposes of clarity, the following detailed description
discusses the features of article of footwear 100, also referred to
simply as article 100. However, it will be understood that other
embodiments may incorporate a corresponding article of footwear
(e.g., a right article of footwear when article 100 is a left
article of footwear) that may share some, and possibly all, of the
features of article 100 described herein and shown in the
figures.
The embodiments may be characterized by various directional
adjectives and reference portions. These directions and reference
portions may facilitate in describing the portions of an article of
footwear. Moreover, these directions and reference portions may
also be used in describing sub-components of an article of footwear
(e.g., directions and/or portions of an inner sole component, a
midsole component, an outer sole component, an upper or any other
components).
For consistency and convenience, directional adjectives are
employed throughout this detailed description corresponding to the
illustrated embodiments. The term "longitudinal" as used throughout
this detailed description and in the claims refers to a direction
extending a length of a component (e.g., an upper or sole
component). In some cases, the longitudinal direction may extend
from a forefoot portion to a heel portion of the component. Also,
the term "lateral" as used throughout this detailed description and
in the claims refers to a direction extending along a width of a
component. In other words, the lateral direction may extend between
a medial side and a lateral side of a component. Furthermore, the
term "vertical" as used throughout this detailed description and in
the claims refers to a direction generally perpendicular to a
lateral and longitudinal direction. For example, in cases where an
article is planted flat on a ground surface, the vertical direction
may extend from the ground surface upward. Additionally, the term
"inner" refers to a portion of an article disposed closer to an
interior of an article, or closer to a foot when the article is
worn. Likewise, the term "outer" refers to a portion of an article
disposed further from the interior of the article or from the foot.
Thus, for example, the inner surface of a component is disposed
closer to an interior of the article than the outer surface of the
component. This detailed description makes use of these directional
adjectives in describing an article and various components of the
article, including an upper, a midsole structure and/or an outer
sole structure.
Article 100 may be characterized by a number of different regions
or portions. For example, article 100 could include a forefoot
portion, a midfoot portion, a heel portion and an ankle portion.
Moreover, components of article 100 could likewise comprise
corresponding portions. Referring to FIG. 1, article 100 may be
divided into forefoot portion 10, midfoot portion 12 and heel
portion 14. Forefoot portion 10 may be generally associated with
the toes and joints connecting the metatarsals with the phalanges.
Midfoot portion 12 may be generally associated with the arch of a
foot. Likewise, heel portion 14 may be generally associated with
the heel of a foot, including the calcaneus bone. Article 100 may
also include an ankle portion 15 (which may also be referred to as
a cuff portion). In addition, article 100 may include lateral side
16 and medial side 18. In particular, lateral side 16 and medial
side 18 may be opposing sides of article 100. Furthermore, both
lateral side 16 and medial side 18 may extend through forefoot
portion 10, midfoot portion 12, heel portion 14 and ankle portion
15.
FIG. 2 illustrates an exploded isometric view of an embodiment of
article of footwear 100. FIGS. 1-2 illustrate various components of
article of footwear 100, including an upper 102 and a sole
structure 103.
Generally, upper 102 may be any type of upper. In particular, upper
102 may have any design, shape, size and/or color. For example, in
embodiments where article 100 is a basketball shoe, upper 102 could
be a high top upper that is shaped to provide high support on an
ankle. In embodiments where article 100 is a running shoe, upper
102 could be a low top upper.
In some embodiments, upper 102 includes opening 114 that provides
entry for the foot into an interior cavity of upper 102. In some
embodiments, upper 102 may also include a tongue (not shown) that
provides cushioning and support across the instep of the foot. Some
embodiments may include fastening provisions, including, but not
limited to: laces, cables, straps, buttons, zippers as well as any
other provisions known in the art for fastening articles. In some
embodiments, a lace 125 may be applied at a fastening region of
upper 102.
An upper could be formed from a variety of different manufacturing
techniques resulting in various kinds of upper structures. For
example, in some embodiments, an upper could have a braided
construction, a knitted (e.g., warp-knitted) construction or some
other woven construction. In an exemplary embodiment, upper 102 may
be a knitted upper.
In some embodiments, sole structure 103 may be configured to
provide traction for article 100. In addition to providing
traction, sole structure 103 may attenuate ground reaction forces
when compressed between the foot and the ground during walking,
running or other ambulatory activities. The configuration of sole
structure 103 may vary significantly in different embodiments to
include a variety of conventional or non-conventional structures.
In some cases, the configuration of sole structure 103 can be
configured according to one or more types of ground surfaces on
which sole structure 103 may be used. Examples of ground surfaces
include, but are not limited to: natural turf, synthetic turf,
dirt, hardwood flooring, as well as other surfaces.
Sole structure 103 is secured to upper 102 and extends between the
foot and the ground when article 100 is worn. In different
embodiments, sole structure 103 may include different components.
In the exemplary embodiment shown in FIGS. 1-2, sole structure 103
may include inner sole component 120, midsole component 122 and a
plurality of outer sole members 124. In some cases, one or more of
these components may be optional.
In different embodiments, upper 102 and sole structure 103 could be
joined in various ways. In some embodiments, upper 102 could be
joined to inner sole component 120, e.g., using an adhesive or by
stitching. In other embodiments, upper 102 could be joined to
midsole component 122, for example, along sidewall portion 142. In
still other embodiments, upper 102 could be joined with both inner
sole component 120 and midsole component 122. Moreover, these
components may be joined using any methods known in the art for
joining sole components with uppers, including various lasting
techniques and provisions (e.g., board lasting, slip lasting,
etc.).
In different embodiments, the attachment configurations of various
components of article 100 could vary. For example, in some
embodiments, inner sole component 120 could be bonded or otherwise
attached to midsole component 122. Such bonding or attachment could
be accomplished using any known methods for bonding components of
articles of footwear, including, but not limited to: adhesives,
films, tapes, staples, stitching, or other methods. In some other
embodiments, it is contemplated that inner sole component 120 may
not be bonded or attached to midsole component 122, and instead
could be free-floating. In at least some embodiments, inner sole
component 120 may have a friction fit with central recess 148 of
midsole component 122.
Outer sole members 124 may be likewise bonded or otherwise attached
to midsole component 122. Such bonding or attachment could be
accomplished using any known methods for bonding components of
articles of footwear, including, but not limited to adhesives,
films, tapes, staples, stitching, or other methods.
It is contemplated that in at least some embodiments, two or more
of inner sole component 120, midsole component 122 and/or outer
sole members 124 could be formed and/or bonded together during a
molding process. For example, in some embodiments, upon forming
midsole component 122, inner sole component 120 could be molded
within central recess 148.
Referring now to FIG. 2, in some embodiments, inner sole component
120 may be configured as an inner layer for a midsole. For example,
as discussed in further detail below, inner sole component 120 may
be integrated, or received, into a portion of midsole component
122. However, in other embodiments, inner sole component 120 could
function as an insole layer and/or as a strobel layer. Thus, in at
least some embodiments, inner sole component 120 could be joined
(e.g., stitched or glued) to lower portion 104 of upper 102 for
purposes of securing sole structure 103 to upper 102.
Inner sole component 120 may have an inner surface 132 and an outer
surface 134. Inner surface 132 may generally be oriented towards
upper 102. Outer surface 134 may be generally oriented towards
midsole component 122. Furthermore, a peripheral sidewall surface
136 may extend between inner surface 132 and outer surface 134.
Midsole component 122 may be configured to provide cushioning,
shock absorption, energy return, stability, support, as well as
possibly other provisions. To this end, midsole component 122 may
have a geometry that provides structure and support for article
100. Specifically, midsole component 122 may be seen to have a
lower portion 140 and a sidewall portion 142. Sidewall portion 142
may extend around the entire midsole periphery 144 of midsole
component 122. As seen in FIG. 1, sidewall portion 142 may
partially wrap up the sides of article 100 to provide increased
support along the base of the foot.
Midsole component 122 may further include an inner surface 150 and
an outer surface 152. Inner surface 150 may be generally oriented
towards upper 102, while outer surface 152 may be oriented
outwardly. Furthermore, in the exemplary embodiment, midsole
component 122 includes a central recess 148 disposed in inner
surface 150. Central recess 148 may generally be sized and
configured to receive inner sole component 120.
In some embodiments, midsole component 122 may include a plurality
of holes. In the exemplary embodiment shown in FIG. 2, none of the
plurality of holes is visible within central recess 148. In this
embodiment, all of the holes are blind holes that are open in outer
surface 152 and terminate between outer surface 152 and inner
surface 150.
In different embodiments, midsole component 122 may generally
incorporate various provisions associated with midsoles. For
example, in one embodiment, a midsole component may be formed from
a polymer foam material that attenuates ground reaction forces
(i.e., provides cushioning) during walking, running, and other
ambulatory activities. In various embodiments, midsole components
may also include fluid-filled chambers, plates, moderators, or
other elements that further attenuate forces, enhance stability, or
influence the motions of the foot, for example.
As seen in FIG. 2, plurality of outer sole members 124 comprises
four distinct outer sole members. Although the exemplary embodiment
includes four different outer sole members, other embodiments could
include any other number of outer sole members. In another
embodiment, for example, only a single outer sole member may be
present. In still another embodiment, only two outer sole members
may be used. In still another embodiment, only three outer sole
members could be used. In still other embodiments, five or more
outer sole members could be used.
Generally, an outer sole member may be configured as a ground
contacting member. In some embodiments, an outer sole member could
include properties associated with outsoles, such as durability,
wear-resistance and increased traction. In other embodiments, an
outer sole member could include properties associated with a
midsole, including cushioning, strength and support. In the
exemplary embodiment, plurality of outer sole members 124 may be
configured as outsole-like members that enhance traction with a
ground surface while maintaining wear resistance.
Embodiments can include provisions to facilitate expansion and/or
adaptability of a sole structure during dynamic motions. In some
embodiments, a sole structure may be configured with auxetic
provisions. In particular, one or more components of the sole
structure may be capable of undergoing auxetic motions (e.g.,
expansion and/or contraction).
Sole structure 103 as shown in FIGS. 1-11 and as described further
in detail below, has an auxetic structure or configuration. Sole
structures comprising auxetic structures are described in U.S.
Patent Application Publication 2015/0075033 (the '033 Publication),
the entirety of which is hereby incorporated by reference.
As described in the '033 Publication, auxetic materials have a
negative Poisson's ratio. When under tension in a first direction,
the dimensions of the auxetic materials increase both in the first
direction and in a second direction orthogonal or perpendicular to
the first direction. This property of an auxetic material is
illustrated in FIGS. 4 and 5.
As seen in FIG. 3, sole structure 103 may include a plurality of
holes 300 (shown in FIGS. 4 and 5), which include plurality of heel
holes 310 and plurality of forefoot holes 320. As used herein, the
term "hole" refers to any hollowed area or recessed area in a
component. In some cases, a hole may be a through hole, in which
the hole extends between two opposing surfaces of a component. In
other cases, a hole may be a blind hole, in which the hole may not
extend through the entire thickness of the component and may
therefore only be open on one side. Moreover, as discussed in
further detail below, a component may utilize a combination of
blind holes with different degrees of penetration into the
midsoles. Furthermore, the term "hole" may be used interchangeably
in some cases with "aperture" or "recess".
In different embodiments, the geometry of one or more holes could
vary. Examples of different geometries that could be used for an
auxetic sole structure are disclosed in the '033 Publication.
Moreover, embodiments could also utilize any other geometries, such
as utilizing sole portions with parallelogram geometries or other
polygonal geometries that are arranged in a pattern to provide the
sole with an auxetic structure. In the exemplary embodiment, each
hole of plurality of holes 300 has a tri-star geometry, including
three arms or points extending from a common center.
Plurality of holes 300 (shown in FIGS. 4 and 5) may be arranged on
sole structure 103 in an auxetic pattern, or auxetic configuration.
In other words, plurality of holes 300 may be arranged on midsole
component 122 and/or outer sole members 124 in a manner that allows
those components to undergo auxetic motions, such as expansion or
contraction. An example of auxetic expansion, which occurs as the
result of the auxetic configuration of plurality of holes 300, is
shown in FIGS. 4 and 5. Initially, in FIG. 4, sole structure 103 is
in a non-tensioned state. In this state, plurality of holes 300
have an un-tensioned area. For purposes of illustration, only a
region 400 of midsole component 122 is shown, where region 400
includes a subset of holes 402.
As tension is applied across sole structure 103 along an exemplary
linear first direction 410 (e.g., a longitudinal direction), as
shown in FIG. 5, sole structure 103 undergoes auxetic expansion.
That is, sole structure 103 expands along first direction 410
(e.g., a longitudinal direction), as well as in a second direction
412 (e.g., a lateral direction) that is perpendicular to first
direction 410. In FIG. 5, the representative region 400 is seen to
expand in both first direction 410 and second direction 412
simultaneously, as subset of holes 402 increase in size.
Embodiments can include provisions for varying the degree to which
some portions of a sole structure (including portions of a midsole
component and/or outer sole members) may undergo auxetic expansion.
Because expansion of the sole structure may result in increased
surface contact and/or increased flexibility for regions of the
sole structure, varying the degree to which different regions or
portions expand (or contract) under tension (or compression) may
allow the traction, cushioning, stability, and/or flexibility
properties of those different regions to be tuned.
Such variation may be used to tune responses of the midsole
component in different regions. For example, the midsole may be
designed so that auxetic expansion in a heel may be greater in
response to a hard heel strike than for a softer heel strike.
Further, the same midsole may be designed for increased stability
in the forefoot.
Varying the degree to which a midsole component undergoes auxetic
expansion can be achieved by varying the properties of different
openings. The tuning effect may be achieved using different types
of auxetic structures in different regions of the midsole while
using patterns of different types of auxetic structures within a
region of the midsole. For example, a particular auxetic shape or
size of an auxetic shape may be selected to control the amount of
auxetic expansion of any particular auxetic structure. Selecting a
pattern or combination of auxetic shapes/sized for a region can
allow the region to be tuned to various performance
characteristics. Some performance characteristics may be more
cushioning for hard impacts, more stability to control rolling
tendencies, and/or customized cushioning based upon a user
profile.
As shown above in FIG. 2 as well as in FIG. 3, all of the auxetic
structures on midsole component 122 are blind holes having a
tri-star geometry, though in other embodiments, the particular
auxetic shape may differ. In the embodiment shown in FIG. 3, heel
portion 14 contains a plurality of heel portion holes 310 (also
referred to simply as "heel holes 310") and forefoot portion 10
contains a plurality of forefoot portion holes 320 (also referred
to simply as "forefoot holes 320"). While midfoot portion 12 does
not contain any holes in this embodiment, those of skill in the art
may position holes in midfoot portion 12 as desired to achieve
various performance characteristics and midsole responses.
As shown in FIG. 3, midsole component 122 has different types of
auxetic holes disposed in predetermined patterns to tune the
performance characteristics of midsole component 122. In the
embodiments shown herein, the different types of auxetic holes
differ based on the depth of penetration into an interior of
midsole component 122. Midsole component 122 has an initial midsole
heel thickness 600 (shown in FIG. 6) defined by inner surface 150
and outer surface 152. Because all of the holes of the present
embodiment are blind holes, the holes are cut into or visible from
only one of inner surface 150 and outer surface 152 and extend into
and terminate within initial midsole heel thickness 600. For the
sake of simplicity, all of the holes discussed herein are formed in
or are visible from outer surface 152. As will be recognized by
those of skill in the art, the holes may be formed in or may be
visible from inner surface 150 or a combination of holes formed in
or visible from either inner surface 150 or outer surface 152. As
will be recognized by those of skill in the art, some embodiments
may include through holes, which would be visible from both inner
surface 150 and outer surface 152.
To provide tunability of performance characteristics in midsole
component 122, each portion of midsole component 122 may have
different combinations of auxetic hole types. For example,
plurality of heel portion holes 310 (shown in FIG. 3) includes some
deep holes and some shallow holes arranged in a particular pattern.
The shallow holes are shallower than the deep holes. The deep holes
will expand auxetically to a greater degree than the shallow holes
in response to a similar force. Therefore, the overall auxetic
expansion of a portion of midsole component 122 can be finely
controlled.
For example, in the embodiment shown in FIG. 3, deeper holes or
holes that penetrate further into the interior of midsole component
122 from outer surface 152 are generally positioned towards a
central portion of midsole component 122 in a medial-to-lateral
direction while shallow holes are positioned proximate midsole
periphery 144. In heel portion 14, the deep holes are arranged into
a plurality of deep heel holes 380, while in forefoot portion 10,
the deep holes are arranged into a plurality of deep forefoot holes
390. Similarly, in heel portion 14, the shallow holes are arranged
into a plurality of shallow heel holes 382, while in forefoot
portion 10, the shallow holes are arranged into a plurality of
shallow forefoot holes 392. In both heel portion 14 and forefoot
portion 10, the shallow holes, such as plurality of shallow heel
holes 382 and plurality of shallow forefoot holes 392, are
positioned proximate midsole periphery 144. In both heel portion 14
and forefoot portion 10, the deep holes, such as plurality of deep
heel holes 380 and plurality of deep forefoot holes 390, fill the
space defined by the arrangement of the shallow holes. This pattern
of shallow holes and deep holes may allow for a number of different
responses of midsole component 122 when impacts or other forces are
applied to midsole component 122, as the deep and shallow holes
will auxetically expand to different degrees. In the embodiment
shown in the figures, the shallow holes may constrain the expansion
of the deep holes so that midsole component 122 may respond to a
wider range of impact forces than a similar midsole lacking
constrained holes. Due to the constraining effect of the shallow
holes, at every magnitude, a force cannot expand the deep holes as
much as unconstrained holes. Therefore, the deep holes will reach a
maximum expansion at a higher magnitude force than for
unconstrained holes. The pattern of shallow holes and deep holes
shown in FIG. 3, therefore, increases the ability of heel portion
14 to respond appropriately to a wider range of impact forces.
Consequently, the tunability of heel portion 14 is increased.
For example, in heel portion 14, plurality of shallow heel holes
382 is formed into a single-hole U-shaped pattern that follows the
curvature defined by periphery 144. Plurality of deep heel holes
380 is positioned within the U-shape and extends from medial side
18 of heel portion 14 to lateral side 16 of heel portion 14 while
remaining entirely within the pattern of plurality of shallow heel
holes 382. This pattern of holes in heel portion 14 may accommodate
a number of different types of heel strikes, as the
centrally-located deep holes may expand to provide cushioning while
the peripherally-located shallow holes may expand to a lesser
degree to provide stability. Further, for hard impact forces, the
holes may expand more than for softer heel strikes to provide
greater cushioning and stability by increasing the total area of
the midsole portion. Because the holes are all blind holes, the
different expansion of the holes may be precisely controlled.
Similarly, in forefoot portion 10, plurality of shallow forefoot
holes 392 is formed into a single-hole U-shaped pattern that
follows the curvature defined by periphery 144. Plurality of deep
forefoot holes 390 is positioned within the U-shape and extends
from a medial side 18 of forefoot portion 10 to a lateral side 16
of forefoot portion 10 while remaining entirely within the pattern
of plurality of shallow forefoot holes 392. This pattern of holes
in forefoot portion 10 may accommodate a number of different types
of forefoot forces, as the centrally-located deep holes may expand
to provide cushioning while the peripherally-located shallow holes
may expand to a lesser degree to provide stability.
These responses are shown and discussed with respect to FIGS. 6-11.
FIG. 6 is a cross-sectional view of the midsole of FIG. 3 taken
along line 6-6 though heel portion 14 when midsole component 122 is
not subject to any external forces. This section of midsole
component 122 includes five holes: a central deep heel hole 350, a
medial deep heel hole 354, a lateral deep heel hole 356, a medial
shallow heel hole 352, and a lateral shallow heel hole 353. Central
deep heel hole 350 is disposed approximately midway between medial
side 18 and lateral side 16. Medial shallow heel hole 352 is
positioned proximate medial side 18, and lateral shallow heel hole
353 is positioned proximate lateral side 16. Medial deep heel hole
354 is disposed between central deep heel hole 350 and medial
shallow heel hole 352. Lateral deep heel hole 356 is disposed
between central deep heel hole 350 and lateral shallow heel hole
353. In other embodiments, the number, placement, and spacing of
holes may differ, depending upon the desired response profile.
FIG. 6 clearly shows the depth penetration variation between the
deep holes and the shallow holes. Central deep heel hole 350
extends from outer surface 152 into initial midsole heel thickness
600 a deep heel distance 610. Medial deep heel hole 354 and lateral
deep heel hole 356 both extend the same deep heel distance 610 into
midsole heel thickness 600. Viewed another way, central deep heel
hole 350 may terminate within initial midsole heel thickness 600 a
first heel distance 614 from inner surface 150.
Medial shallow heel hole 352 extends from outer surface 152 into
initial midsole heel thickness 600 a shallow distance 612, where
shallow distance 612 is less than deep heel distance 610. Lateral
shallow heel hole 353 extends the same shallow distance 612 into
initial midsole heel thickness 600. Viewed another way, medial
shallow heel hole 352 may terminate a second heel distance 616 from
inner surface 150. Second heel distance 616 is greater than first
heel distance 614.
Deep heel distance 610 is greater than shallow distance 612, so
that the deep holes penetrate further into initial midsole heel
thickness 600 than do the shallow holes. Initial midsole heel
thickness 600 may be any thickness known in the art suitable for
midsoles. Deep heel distance 610 may be any distance that
terminates within initial midsole heel thickness 600, and,
therefore, depends upon factors such as initial midsole heel
thickness 600, desired maximum auxetic expansion, and durability.
Deep heel distance 610 may be selected for both auxetic expansion
and durability; the termination point of deep heel distance 610 may
be selected so that first heel distance 614 may yield sufficient
material to withstand repeated expansion of central deep heel hole
350 without failure.
FIG. 6 shows heel portion 14 in an unflexed and unexpanded
configuration. As such central deep heel hole 350 has an initial or
first auxetic width 620. Similarly, all deep heel holes have a
similar initial auxetic width at a similar position along the arm
of the tri-star hole. However, because the arm of the tri-star hole
tapers to a point, the initial auxetic widths of the other deep
holes, medial deep heel hole 354 and lateral deep heel hole 356, at
this particular cross-section may be different from that of central
deep heel hole 350 because the center points of medial deep heel
hole 354 and lateral deep heel hole 356 are offset from the center
point of central deep heel hole 350.
Similar to heel portion 14, forefoot portion 10 may be designed for
tunable performance characteristics. FIG. 7 is a cross-sectional
view of the midsole of FIG. 3 taken along line 7-7 through forefoot
portion 10 when midsole component 122 is not subject to any
external forces. This section of midsole component 122 passes
through six holes: a first deep forefoot hole 360, a second deep
forefoot hole 363, a third deep forefoot hole 364, a fourth deep
forefoot hole 365, a medial shallow forefoot hole 361, and a
lateral shallow forefoot hole 362. First deep forefoot hole 360,
second deep forefoot hole 363, third deep forefoot hole 364, and
fourth deep forefoot hole 365 are arranged between medial side 18
and lateral side 16. Medial shallow forefoot hole 361 is positioned
proximate medial side 18, and lateral shallow forefoot hole 362 is
positioned proximate lateral side 16.
FIG. 7 clearly shows the depth penetration variation between the
deep holes and the shallow holes in forefoot portion 10. First deep
forefoot hole 360 extends from outer surface 152 into midsole
forefoot thickness 700 a deep forefoot distance 710. Second deep
forefoot hole 363, third deep forefoot hole 364, and fourth deep
forefoot hole 365 each extend the same deep forefoot distance 710
into midsole forefoot thickness 700. Viewed another way, first deep
forefoot hole 360 may terminate a first forefoot distance 714 from
inner surface 150.
Medial shallow forefoot hole 361 extends from outer surface 152
into midsole forefoot thickness 700 a shallow distance 712. Lateral
shallow forefoot hole 362 extends the same shallow distance 712
into midsole forefoot thickness 700. Viewed another way, medial
shallow forefoot hole 361 may terminate a second forefoot distance
716 from inner surface 150.
Deep forefoot distance 710 is greater than shallow distance 712, so
that the deep holes penetrate further into midsole forefoot
thickness 700 than do the shallow holes. Midsole forefoot thickness
700 may be any thickness known in the art suitable for midsoles.
Deep forefoot distance 710 may be any distance that terminates
within midsole forefoot thickness 700, and, therefore, depends upon
midsole forefoot thickness 700 and other factors such as the
desired maximum expansion. Deep forefoot distance 710 may be
selected for both auxetic expansion and durability; the termination
point of deep forefoot distance 710 may be selected so that first
forefoot distance 714 may yield sufficient material to withstand
repeated expansion of first deep forefoot hole 360 without failure,
such as breaking or material separation in the narrowest part of
the midsole.
FIGS. 8-11 show how the same midsole with auxetic structures,
midsole component 122, may have different cushioning and stability
responses when impacted with forces of different magnitude. FIGS. 8
and 9 show how midsole component 122 may respond to a high
magnitude impact, such as a hard heel strike. A first user 800 may
run wearing an article of footwear like article of footwear 100
that incorporates a midsole like midsole component 122. First user
800 may impact a surface 813 such as the ground with a hard heel
strike, which may impart a hard force 830 to midsole component 122.
Midsole component 122 may expand auxetically to hard expanded state
822. In hard expanded state 822, at least one of the holes of heel
portion 14 expands in an auxetic manner in response to hard force
830 to expand heel portion 14. As shown in FIGS. 8 and 9, the width
of heel portion 14 expands to a hard force width 975 and the length
of heel portion 14 expands to a hard force length 970. Hard force
width 975 is greater than initial heel portion width 375 as shown
in FIG. 3. Hard force length 970 is also greater than initial heel
portion length 370 as shown in FIG. 3.
The total area of heel portion 14 increases in response to hard
force 830. The increase in area is due to the expansion of the
holes in both longitudinal direction 410 and lateral direction 412.
As shown in FIG. 8, for example, the holes may take on an expanded
deep hole width 820 and an expanded shallow hole width 812 in an
auxetic manner as discussed above with respect to FIGS. 4 and 5. As
such, an increase in length corresponds to an increase in width. In
some embodiments, the material of midsole component 122 may
compress in response to hard force 830 to locally reduce the
thickness of midsole component 122 from initial midsole heel
thickness 600 (shown in FIG. 6) to hard force thickness 802. Hard
force thickness 802 may be less than initial midsole heel thickness
600, though in some embodiments, the energy of hard force 830 may
be entirely absorbed by the expansion of the holes. As will be
apparent to those of skill in the art, once hard force 830 is no
longer being applied to midsole component 122, the holes in midsole
may contract and midsole component 122 may return to the initial
configuration shown in FIG. 3.
FIGS. 10 and 11 show how midsole component 122 may respond to a
lower magnitude impact, such as a soft heel strike. A second user
1000 may run wearing an article of footwear like article of
footwear 100 that incorporates a midsole like midsole component
122. Second user 1000 may impact surface 813 such as the ground
with a softer heel strike than first user 800, which may impart a
weak force 1030 to midsole component 122. Midsole component 122 may
expand auxetically to weak expanded state 1022. In weak expanded
state 1022, at least one of the holes of heel portion 14 expands in
an auxetic manner in response to weak force 1030. As shown in FIGS.
10 and 11, the width of heel portion 14 expands to a weak force
width 1075 and the length of heel portion 14 expands to a weak
force length 1070. Weak force width 1075 is greater than initial
heel portion width 375 as shown in FIG. 3, but less than hard force
width 975 as shown in FIG. 9. Weak force length 1070 is also
greater than initial heel portion length 370 as shown in FIG. 3,
but less than hard force length 970 as shown in FIG. 9.
The total area of heel portion 14 increases in response to weak
force 1030. The increase in area is due to the expansion of the
holes in both longitudinal direction 410 and lateral direction 412.
As shown in FIG. 10, for example, the holes may take on a weak
expanded deep hole width 1020 and a weak expanded shallow hole
width 1012 in an auxetic manner as discussed above with respect to
FIGS. 4 and 5. As such, an increase in length corresponds to an
increase in width. In some embodiments, the material of midsole
component 122 may compress in response to weak force 1030 to
locally reduce the thickness of midsole component 122 from initial
midsole heel thickness 600 (shown in FIG. 6) to weak force
thickness 1001. In some embodiments, weak force thickness 1001 may
be less than initial midsole heel thickness 600 but greater than
hard force thickness 802. In some embodiments, the energy of weak
force 1030 may be entirely dissipated by the expansion of the
holes. In such embodiments, weak force thickness 1001 may be the
same as initial midsole heel thickness 600. As will be apparent to
those of skill in the art, once weak force 1030 is no longer being
applied to midsole component 122, the holes in midsole may contract
and midsole component 122 may return to the initial configuration
shown in FIG. 3.
As noted above, the pattern of blind holes on midsole component 122
may be distributed so that different portions of midsole component
122 have different performance characteristics. As shown in FIG. 3,
forefoot portion 10 and heel portion 14 may have different
patterns, types, and/or number of blind holes. FIG. 12 is a
longitudinal cross-sectional view of midsole component 122 at a
central lateral position between medial side 18 and lateral side 16
that shows the different numbers and depths of heel holes 310 and
forefoot holes 320 in this embodiment.
As shown, both forefoot portion 10 and heel portion 14 have
relatively deep holes and relatively shallow holes. For example,
forefoot portion 10 in this embodiment includes plurality of deep
forefoot holes 390 and plurality of shallow forefoot holes 392
(shown in FIG. 3). Similarly, heel portion 14 includes plurality of
deep heel holes 380 and plurality of shallow heel holes 382 (shown
in FIG. 3). The number of holes in forefoot portion 10 differs from
the number of holes in heel portion 14. For example, in this
embodiment, forefoot portion 10 includes five deep forefoot holes
1261 in this lateral position while heel portion 14 includes only
three deep heel holes 1250. The different number of holes may be
partially due to different sizes of forefoot portion 10 and heel
portion 14. For example, in some embodiments, forefoot portion 10
may be larger than heel portion 14. In some embodiments, the
patterns of auxetic holes may cover an entirety of forefoot portion
10 and an entirety of heel portion 14. Because the area of forefoot
portion 10 may be greater than an area of heel portion 14, the
number of auxetic holes disposed in forefoot portion 10 may be
greater than the number of similar surface area auxetic holes
disposed in heel portion 14. Further, as shown in FIG. 12,
plurality of forefoot holes 320 may be smaller than heel holes 310.
Either of these reasons may account for the different number of
holes in forefoot portion 10 than in heel portion 14.
However, the number of holes in the different portions may be due
to the intended tunable performance characteristics of the
different portions. For example, heel portion 14 may be primarily
designed to provide cushioning for harder impacts, such as heel
strikes, while forefoot portion 10 may be primarily designed to
provide stability when a foot rolls from a heel strike to push off
from a surface for the next step. While both portions, heel portion
14 and forefoot portion 10, may include both cushioning and
stability features, the dominant intended characteristic for a
portion may control the pattern, type, and number of auxetic holes
in the portion.
In addition to number, the sizes of the holes may differ between
forefoot portion 10 and heel portion 14. As shown in FIG. 12, heel
holes 310 are generally larger than forefoot holes 320. For
example, first deep heel hole 1210 may extend from outer surface
152 into midsole component 122 to deep heel distance 610, while
first deep forefoot hole 1260 may extend from outer surface 152
into midsole component 122 to deep forefoot distance 1230. In some
embodiments, deep heel distance 610 may be greater than deep
forefoot distance 1230. The different deep hole distances may be
provided so that heel portion 14 may expand auxetically to a
greater degree than forefoot portion 10. Consequently, in some
embodiments, heel portion 14 may provide more cushioning than
forefoot portion 10. Forefoot portion 10 may provide more stability
and support than heel portion 14, even though the surface pattern
of holes looks similar between the portions.
FIGS. 12-14 show how heel portion 14 and forefoot portion 10 react
to the different types of forces to which those portions are
subjected. As shown in FIG. 13, heel portion 14 may be subjected to
a heel strike that imparts a heel force 1300 to heel portion 14.
For the purposes of this example, only heel portion 14 is subjected
to heel force 1300; forefoot portion 10 is lifted away from the
impact surface.
Heel force 1300 causes heel holes 310 (shown in FIG. 3) to expand.
Each hole, such as first deep heel hole 1210, may increase in
length. For example, first deep heel hole 1210 may have an initial
deep heel hole length 1220. Under the pressure of heel force 1300,
initial deep heel hole length 1220 increases to expanded deep heel
hole length 1320. In the embodiment shown in FIG. 13, the expansion
of the holes corresponds to an overall expansion of heel portion
14, shown in FIG. 13 as an increase in the length of heel portion
14. As shown in FIG. 12, heel portion 14 has an initial heel length
1270. Once auxetically expanded, as shown in FIG. 13, heel portion
14 has an expanded auxetic length 1370, which is greater than
initial heel length 1270. As will be apparent to those of skill in
the art, while not shown, heel portion 14 of midsole component 122
may also expand in a medial-to-lateral direction, as discussed
above. Forefoot portion 10 remains unchanged in this embodiment,
though forefoot portion 10 may expand slightly in some
embodiments.
Heel holes 310 may be selected to provide cushioning to impacts
like heel force 1300 from a heel strike. As discussed above, heel
holes 310 generally extend further into midsole component 122 than
do forefoot holes 320. The size of heel holes 310 allows heel holes
310 to expand more than forefoot holes 320, and, consequently, to
provide more cushioning more than forefoot holes 320. Additionally,
when auxetically expanded, heel portion 14 will expand in both a
longitudinal direction and a lateral direction as shown in FIG. 9.
The large heel surface area can also assist in the stability of
heel portion 14 by increasing traction between heel portion 14 and
the impact surface so that heel portion 14 is less likely to
slip.
As shown in FIG. 14, forefoot portion 10 may be subjected to a
rolling push-off that imparts a longitudinal force 1400 to forefoot
portion 10. The rolling motion of the foot stretches forefoot
portion 10. For the purposes of this example, only forefoot portion
10 is subjected to longitudinal force 1400; heel portion 14 is
lifted away from the impact surface (not shown).
Longitudinal force 1400 causes forefoot holes 320 to expand. Each
hole, such as first deep forefoot hole 1260, may increase in
length. For example, first deep forefoot hole 1260 may have an
initial deep heel hole length 1220. Under the pressure of
longitudinal force 1400, initial deep forefoot hole length 1265
increases to expanded deep forefoot hole length 1465. In the
embodiment shown in FIG. 14, the expansion of the holes corresponds
to an overall expansion of forefoot portion 10, shown in FIG. 14 as
an increase in the length of forefoot portion 10. As shown in FIG.
12, forefoot portion 10 has an initial forefoot length 1280. Once
auxetically expanded, as shown in FIG. 14, forefoot portion 10 has
an expanded auxetic length 1480, which is greater than initial
forefoot length 1280. As will be apparent to those of skill in the
art, while not shown, forefoot portion 10 of midsole component 122
may also auxetically expand in a medial-to-lateral direction, as
discussed above. Heel portion 14 remains unchanged in this
embodiment. In other embodiments, heel portion 14 may expand
slightly.
Forefoot holes 320 may be selected to provide stability when
subjected to forces like rolling longitudinal force 1400. As
discussed above, forefoot holes 320 generally do not extend as far
into midsole component 122 as heel holes 310. The relatively
shallow size of forefoot holes 320 allows forefoot holes 320 to
resist expansion more than heel holes 310, and, consequently, to
provide more of a countering force against rolling in an unintended
manner. Additionally, when auxetically expanded, forefoot portion
10 will expand in both a longitudinal direction and a lateral
direction as shown in FIG. 11. The larger surface area can further
assist in stability of forefoot portion 10 by providing a larger
platform for the forefoot of a user.
As noted above, the cushioning elements described herein may be
utilized with various components or articles. For example, the
degree of elasticity, cushioning, and flexibility of a sole
component such as a sole member can be important factors associated
with comfort and injury prevention for an article of footwear.
FIGS. 15-20 depict an embodiment of a method of designing a
customized sole member for an article of footwear. Additional
embodiments of methods of designing a customized sole member may be
found in U.S. Patent Publication Number 2016/0345667 to Kohatsu,
currently U.S. Ser. No. 14/722,826, titled "Article of Footwear
Comprising a Sole Member with Geometric Patterns", and filed on May
27, 2015; the entirety of this application is incorporated herein
by reference.
FIG. 15 shows the three-dimensional shape of plantar surface 2002
of a foot 2000 being measured using a data collection apparatus
2028. In some cases, data collection apparatus 2028 can be a force
platform. In other cases, data collection apparatus 2028 can
comprise one of the commercially available systems for measuring
plantar pressure (e.g., Emed sensor platform, Pedar insole system,
F-Scan system, Musgrave footprint system, etc.). Plantar pressure
measurement systems can provide a means of obtaining specialized
information regarding a foot that can be used to customize footwear
for individuals. In some embodiments, the magnitude of pressure can
be determined by dividing the measured force by the known area of
the sensor or sensors evoked while the foot was in contact with the
supporting surface in some embodiments.
For purposes of reference, foot 2000, representations of foot 2000,
components associated with foot 2000 (such as an article of
footwear, an upper, a sole member, a computer-aided design of foot
2000, and other components/representations) may be divided into
different portions. Foot 2000 may include a forefoot portion 2004,
a midfoot portion 2006 and a heel portion 2008. Forefoot portion
2004 may be generally associated with the toes and joints
connecting the metatarsals with the phalanges. Midfoot portion 2006
may be generally associated with the metatarsals of a foot. Heel
portion 2008 may be generally associated with the heel of a foot,
including the calcaneus bone. In addition, foot 2000 may include a
lateral side 2010 and a medial side 2012. In particular, lateral
side 2010 and medial side 2012 may be associated with opposing
sides of foot 2000. Furthermore, both lateral side 2010 and medial
side 2012 may extend through forefoot portion 2004, midfoot portion
2006, and heel portion 2008. It will be understood that forefoot
portion 2004, midfoot portion 2006, and heel portion 2008 are only
intended for purposes of description and are not intended to
demarcate precise portions of foot 2000. Likewise, lateral side
2010 and medial side 2012 are intended to represent generally two
sides of foot 2000, rather than precisely demarcating foot 2000
into two halves.
Furthermore, in the examples depicted in FIGS. 15 and 16, foot 2000
and/or a virtual scan 2100 of a foot may include a medial arch area
2020, associated with an upward curve along medial side 2012 of
midfoot portion 2006, and a lateral arch area 2022, associated with
an upward curve along lateral side 2010 of midfoot portion 2006.
The portion corresponding to lateral arch area 2022 is best seen in
FIG. 16, which illustrates a computer screen or virtual image of
digitized three-dimensional foot data. As described below, the
curvature of medial arch area 2020 and lateral arch area 2022 may
vary from one foot to another. In addition, foot 2000 includes a
transverse arch 2024 that extends in a direction generally aligned
with lateral axis 190 near forefoot portion 2004 along plantar
surface 2002. Foot 2000 also includes a heel prominence 2026, which
is the prominence located in heel portion 2008 of foot 2000. As
shown in FIG. 15, foot 2000 is illustrated as a left foot; however,
it should be understood that the following description may equally
apply to a mirror image of a foot or, in other words, a right
foot.
Although the embodiments throughout this detailed description
depict components configured for use in athletic articles of
footwear, in other embodiments, the components may be configured to
be used for various other kinds of footwear including, but not
limited to, hiking boots, soccer shoes, football shoes, sneakers,
running shoes, cross-training shoes, rugby shoes, basketball shoes,
baseball shoes as well as other kinds of shoes. Moreover, in some
embodiments, components may be configured for various kinds of
non-sports related footwear, including, but not limited to,
slippers, sandals, high-heeled footwear, loafers as well as any
other kinds of footwear.
Components associated with an article of footwear are generally
made to fit various sizes of feet. In the embodiments shown, the
various articles are configured with approximately the same
footwear size. In different embodiments, the components could be
configured with any footwear sizes, including any conventional
sizes for footwear known in the art. In some embodiments, an
article of footwear may be designed to fit the feet of a child. In
other embodiments, an article of footwear may be designed to fit
the feet of an adult. Still, in other embodiments, an article of
footwear may be designed to fit the feet of a man or a woman.
Referring to FIGS. 15 and 16, a first step of the present method is
to collect data related to foot 2000, such as using a barefoot
pressure measurement or other data, from the foot being measured on
data collection apparatus 2028. Data collection apparatus 2028 may
include provisions for capturing information about an individual's
feet. Specifically, in some embodiments, data collection apparatus
2028 may include provisions to capture geometric information about
one or more feet. This geometric information can include size
(e.g., length, width, and/or height) as well as three-dimensional
information corresponding to the customer's feet (e.g., forefoot
geometry, midfoot geometry, heel geometry, and ankle geometry). In
at least one embodiment, the captured geometric information for a
customer's foot can be used to generate a three-dimensional model
of the foot for use in later stages of manufacturing. In
particular, the customized foot information can include at least
the width and length of the foot. In some cases, the customized
foot information may include information about the
three-dimensional foot geometry. Customized foot information can be
used to create a three-dimensional model of the foot. Embodiments
may include any other provisions for capturing customized foot
information. The present embodiments could make use of any of the
methods and systems for forming an upper disclosed in Bruce, U.S.
Patent Publication Number 2016/0166011 (now U.S. patent application
Ser. No. 14/565,582, filed Dec. 10, 2014), titled "Portable
Manufacturing System for Articles of Footwear," the entirety of
which is hereby incorporated by reference.
Some embodiments could use any of the systems, devices, and methods
for imaging a foot as disclosed in Leedy et al., U.S. Patent
Publication Number 2013/0258085, published Oct. 3, 2013, and titled
"Foot Imaging and Measurement Apparatus," (previously U.S. patent
application Ser. No. 13/433,463, filed Mar. 29, 2012), the entirety
of which is hereby incorporated by reference.
In FIG. 16, a screen 2102 displays virtual scan 2100 of plantar
pressure distributions for the foot of FIG. 15. Virtual scan 2100
may provide a measured foot image or representation, including
various distinct portions to indicate the pressures applied or
experienced by foot 2000 over its plantar surface 2002, as shown in
FIG. 15. In one example, pressures can include a first pressure
area 2104, a second pressure area 2106, a third pressure area 2108,
a fourth pressure area 2110, and a fifth pressure area 2112. An
additional pressure area 2114 is indicated where plantar surface
2002 did not make an impressionable contact with the surface of
data collection apparatus 2028. In some embodiments, colors (not
shown in FIG. 16) can be included in virtual scan 2100 to more
readily distinguish variations within the measured pressure data.
It should be noted that in other embodiments, different, fewer, or
more pressure areas may be measured or indicated.
As seen in FIG. 16, in some embodiments, the data collected may
include virtual scan 2100 of foot 2000. In some embodiments,
virtual scan 2100 may be used to assess the three-dimensional shape
and obtain digital data in a two-dimensional or a three-dimensional
reference frame. In other embodiments, virtual scan 2100 can
provide a baseline shape for a footwear component. In one
embodiment, three-dimensional scanned images may be used to measure
the overall shape of a person's feet, and obtain two-dimensional
measurements such as an outline, length, and width of foot 2000.
Obtaining foot geometry can establish a baseline record for the
person in one embodiment. In some embodiments, other input may also
be provided to supplement information regarding the person being
measured. In different embodiments, additional data such as toe
height information may also be obtained. In other embodiments,
plaster casts of a person's foot may be taken and digitized.
Additionally, other digital or imaging techniques that may be
employed to capture two- and three-dimensional foot shape and
profile can be used to construct and/or supplement virtual scan
2100. In other embodiments, the person whose foot is being measured
may provide answers to questions describing the person's physical
characteristics, limitations, preferences, and/or personal
lifestyle, which may impact design of the various parts described
herein.
In different embodiments, a sole member may provide one or more
functions for an article of footwear. In FIG. 17, an image of a
template of a sole member 2200 is displayed on a screen 2202. In
some embodiments, sole member 2200 may attenuate ground reaction
forces when compressed between the foot and the ground during
walking, running, or other ambulatory activities. The configuration
of sole member 2200 may vary significantly in different embodiments
to include a variety of conventional or non-conventional
structures. In some cases, the configuration of sole member 2200
can be selected or customized according to one or more types of
ground surfaces on which sole member 2200 may be used. Examples of
ground surfaces include, but are not limited to, natural turf,
synthetic turf, dirt, as well as other surfaces.
Upon obtaining measurements of foot 2000 (see FIG. 15), sole member
2200 may be adjusted or altered in different embodiments. As seen
in the virtual representation depicted in FIG. 18, using the data
collected from the steps above, a first custom sole 2300 may be
designed. In some embodiments, the design may utilize an
application of an integrated computer-aided design such as a
computer-automated manufacturing (CAD-CAM) process. Sole member
2200, or any other template previously selected, may be provided as
an input to the computer design program. In one embodiment, the
three-dimensional foot shape data from virtual scan 2100 in FIG. 16
is also provided to the program.
In different embodiments, virtual scan 2100 may provide information
regarding foot shape and pressure to allow the appropriate fit and
comfort within the article of footwear. The information may be used
to form first custom sole 2300. In some embodiments, data from
virtual scan 2100 may be superimposed or otherwise incorporated
into the template of sole member 2200 (see FIGS. 16 and 22). For
example, there may be a process of aligning the data representing
the plantar pressures of foot 2000 with sole member 2200 and
generating a partial or complete design of first custom sole 2300.
In one embodiment, pressure contour lines 2306 may be generated
during the design of first custom sole 2300. The pressure
distribution may be adjusted to a "best-fit" position based upon
user input in some embodiments. Once the distribution is finalized,
a resiliency profile may be created. For purposes of this
disclosure, a resiliency profile is a personalized pressure
distribution for a user that may include the data collected during
the steps described above. In some embodiments, the resiliency
profile may be utilized in the production of first custom sole
2300. Thus, in one embodiment, after the resiliency profile
comprising an individual's plantar pressure distributions is
aligned with the template of sole member 2200, a customized sole
member may be formed or manufactured.
It should be understood that, in different embodiments, the design
of a sole member may include various modifications. Customized
modifications may provide individual users with a wider range of
comfort and fit. For example, different users may have differences
in the height of the arch of foot 2000. As described above, foot
2000 may include multiple arches. Generally, the arch is a raised
curve on the bottom surface of foot 2000. When the tendons of foot
2000 pull a normal amount, foot 2000 generally forms a moderate or
normal arch. However, when tendons do not pull together properly,
there may be little or no arch. This is called "flat foot" or
fallen arch. Over-pronation of a foot may be common for those with
flat feet. The framework of a foot can collapse, causing the foot
to flatten and adding stress to other parts of the foot.
Individuals with flat feet may need orthotics to control the
flattening of the foot. Moreover, the opposite may also occur,
though high foot arches are less common than flat feet. Without
adequate support, highly arched feet tend to be painful because
more stress is placed on the section of the foot between the ankle
and toes. This condition can make it difficult to fit into shoes.
Individuals who have high arches usually need foot support. It
should be noted that such variations in arch height are one of many
possible examples of customized foot geometry that may be
incorporated into a design.
Referring to FIG. 19, an embodiment of an influence diagram 2400 is
depicted. Influence diagram 2400 reflects some of the factors or
variables that can be considered, incorporated, and/or used during
the generation of the resiliency profile, permitting customization
of tunable performance characteristics 2450 of a sole member.
Tunable performance characteristics may include but are not limited
to cushioning, traction, stability, and support. For example, a
first factor 2410 includes an individual's measured plantar
pressure for each foot, which was discussed above with respect to
FIGS. 20-21. In addition, a second factor 2420 may include the
materials that will be used to form the custom sole member. Third
factor 2430 can be the individual user's own personal preferences
regarding the type or level of cushioning desired. Fourth factor
2440 may be the activity or sport that the user will be generally
engaging in while using the custom sole member. In some cases, the
sole member can be designed or tailored to provide special
cushioning in areas or portions of the sole member that typically
experience more force or pressure from the foot during specific
activities. Thus, in some embodiments, one or more of these factors
can contribute to tunable performance characteristics 2450 of a
sole member. It should be understood that influence diagram 2400 is
provided as an example, and many other factors not listed here may
be included in other embodiments. Furthermore, one or more factors
listed in influence diagram 2400 may be removed from consideration
depending on the desired output or the goal of the custom sole
member.
Once a design has been generated, as with first custom sole 2300,
the sole member may be manufactured. In some embodiments, the
modifications may include portions of the sole member with
apertures 2050 disposed along different portions of the sole
member. In some embodiments, a sole member can be molded in a
manner that creates apertures in the sole member. An article of
footwear including apertures can be formed in any manner. In some
embodiments, apertures can be created in a sole member using any
known methods of cutting or drilling. For example, in one
embodiment, apertures can be created using laser cutting
techniques. Specifically, in some cases, a laser can be used to
remove material from a sole member in a manner that forms apertures
in the sole member. In another embodiment, a hot knife process
could be used for forming apertures in a sole member. Examples of
methods for forming apertures on a sole member are disclosed in
McDonald, U.S. Pat. No. 7,607,241, issued Oct. 27, 2009, titled
"Article of Footwear with an Articulated Sole Structure,"
(previously U.S. patent application Ser. No. 11/869,604, filed Oct.
9, 2007), the entirety of which is hereby incorporated by
reference.
In other embodiments, however, any other type of cutting method can
be used for forming apertures. Furthermore, in some cases, two or
more different techniques can be used for forming apertures. As an
example, in another embodiment, apertures disposed on a side
surface of a sole member can be formed using laser cutting, while
apertures on a lower surface of the sole member could be formed
during a molding process. Still further, different types of
techniques could be used according to the material used for a sole
member. For example, laser cutting may be used in cases where the
sole member is made of a foam material.
In FIG. 20, a figure depicting an embodiment of a method of forming
first custom sole 2300, including apertures, is shown. Referring to
FIG. 20, apertures 2050 can be applied to or formed in first custom
sole 2300 using a laser drill 2500. In one embodiment, laser drill
2500 may be used to cut away or remove material through thickness
2540 of first custom sole 2300. In other cases, there may be a
greater number of laser drills used. In FIG. 20, a third group of
apertures 2530 along forefoot portion 2004 is being formed along a
surface of first custom sole 2300. First group of apertures 2510 in
heel portion 2008 and second group of apertures 2520 in midfoot
portion 2006 are shown as having been previously formed by laser
drill 2500.
Although only apertures in one general portion are shown being
drilled in this example, it will be understood that a similar
method could be used for creating or forming apertures in any other
portion of first custom sole 2300. It should further be understood
that laser drill 2500 may include provisions for moving along
different directions in order to direct the laser beam to the
desired location. Furthermore, the sole member may be disposed such
that it may be automatically or manually moved to receive a laser
2570 at the appropriate or desired location, such as along forefoot
portion 2004, midfoot portion 2006, and/or heel portion 2008. In
addition, while only one laser drill 2500 is shown in use in FIG.
20, in other embodiments, two, three, four, or more laser drills
may be engaged with the sole member.
In some embodiments, referring to a magnified area 2550, it can be
seen that laser 2570 may contact outer surface 152 of first custom
sole 2300. When laser 2570 contacts the material, it may begin to
remove material and form a hole 2522. As laser 2570 continues to
engage with the material of the sole member, hole 2522 may grow
through thickness 2540 and form a first aperture 2560.
It may be recalled that each aperture may be formed such that they
differ in one or more respects from one another, or they may be
formed in a uniform manner, such that they are substantially
similar in size, length, and shape. Furthermore, it should be
understood that laser drill 2500 may be oriented at an angle
different from that shown in FIG. 20, so that laser drill 2500 can
form apertures 2050 oriented in a diagonal or non-parallel manner
with respect to vertical axis 170, longitudinal axis 180, and/or
lateral axis 190.
While various embodiments of the article of footwear have been
described, the description is intended to be exemplary, rather than
limiting and it will be apparent to those of ordinary skill in the
art that many more embodiments and implementations are possible
that are within the scope of the present disclosure. Any element of
any embodiment may be used with or substituted for another element
in any other embodiment unless specifically restricted.
Accordingly, the presently disclosed article of footwear is not to
be restricted except in light of the attached claims and their
equivalents. Also, various modifications and changes may be made
within the scope of the attached claims.
Other systems, methods, features and advantages of the presently
disclosed article of footwear will be, or will become, apparent to
one of ordinary skill in the art upon examination of the following
figures and detailed description. It is intended that all such
additional systems, methods, features and advantages be included
within this description and this summary, be within the scope of
the present disclosure, and be protected by the following
claims.
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